Optical information storage medium

ABSTRACT

An optical information storage medium includes a substrate and a multilayer polymeric film. The multilayer polymeric film has a first surface and an opposite second surface that extend the length of the multilayer polymeric film. The second surface is adhered to a surface of the substrate. The multilayer polymeric film includes a plurality of coextruded alternating polymeric active data storage layers and polymeric buffer layers.

RELATED APPLICATION

This application is a Continuation-in-Part of U.S. Ser. No. 15/041,928,filed Feb. 11, 2016, Now U.S. Pat. No. 10,229,709, which is aContinuation of U.S. Ser. No. 14/124,890, filed Mar. 12, 2014, U.S. Pat.No. 9,275,671, which is a National Phase Filing of PCT/US2012/041870,filed Jun. 11, 2012, which claims priority from U.S. ProvisionalApplication No. 61/494,966, filed Jun. 9, 2011, the subject matter ofwhich are incorporated herein by reference in their entirety.

GOVERNMENT FUNDING

This invention was made with government support under Grant No.DMR0423914 awarded by The National Science Foundation. The United Statesgovernment may have certain rights to the invention.

TECHNICAL FIELD

The application relates to an optical information storage medium and, inparticular, relates to a three-dimensional multilayer opticalinformation storage medium that is formed using a polymer extrusionprocess.

BACKGROUND

Media capable of patterning by light exposure are a common manifestationof information storage. In one of the oldest techniques, photographicemulsions are used to record the image of the light incident upon it.There is recently an increased demand for storage of information byoptical means, for use in archiving, security tags, 3D representation ofimages, aberration correction, and storage of digital data. In order toachieve the desired optical response or a larger optical response, 3Dmedia are used. Furthermore, the areal information capacity is limitedby the optics of the read/write system. For example, holographicstereograms require small lateral features to achieve high imageresolution, as well as thick media to achieve large image contrast.Additional increases in capacity require additional dimensions, whichmight include the spatial thickness dimension, but also could includecolor, polarization, or phase multiplexing.

The main approaches to entry into the third spatial dimension involveeither multilayer information storage or holographic informationstorage. Multilayer storage can be affected either by physical layers,or optical layering provided by localization near the focus of thelasers using multiphoton absorption. These approaches, however, havesignificant limitations. Holographic storage requires complicated andpotentially costly optical read/write hardware. Similarly, the lasersneeded for multiphoton absorption are more complicated, costly, andintroduce additional sources of noise. Physical multilayering employssimpler hardware, but the manufacturing of multiple layers in thestorage medium has proven to be difficult to scale up economically.

SUMMARY

Embodiments of the application relate to an optical information storagemedium that includes a multilayer film. The multilayer film includes aplurality of extruded alternating active data storage layers and bufferlayers, which separate the active data storage layers. The active datastorage layers and buffer layers have thicknesses that allow the activedata storage layers to be writable to define data voxels (e.g., discretebits, images, shapes, holograms, etc.) within the active data storagelayers that are readable by an optical reading device. The opticalinformation storage medium is compatible in formats including but notlimited to disks, rolls, cards, stickers, paper, or laminated ontoflexible or non-flexible substrates.

The optical information storage medium can be designed to accommodatethree-dimensional data storage that is compatible with existing opticalread/write technology, and an appropriate permanent or reversible one-or multiphoton, linear, non-linear or threshold optical writing scheme.The medium can be applied to the storage of digital information,incorporated onto an information bearing document for security,identification, bar codes, product tracking, tamper resistant packaging,production of information bearing diffractive elements, such asholograms, stereograms, holographic optical element, holographicdiffusers, and photonic paper.

Layering of the physical medium enables information, localized in threedimensions, to be written and subsequently read with highsignal-to-noise. Such enhancement can arise from confinement of theactive data storage layers to thin layers of well-defined separation,providing for precise location of the data during reading, reducedinterlayer cross-talk, reduced parasitic absorption from areas outsideof the focal region, and reduced aberration from having less scatteringmaterial. In addition to the active and buffers layers, other layers maybe readily included in the multilayer film. These other layers canprovide, for example, a signal for tracking depth within the medium, orfor storing metadata, cryptographic information, checksums, codecs, orfirmware.

In some embodiments, the active data storage layers can include amaterial that undergoes an optically induced localized change of opticalproperties when written by the appropriate permanent or reversible one-or multiphoton, linear, non-linear or threshold optical writing process.The change in optical properties can include but is not limited to atleast one of a reversible or irreversible change of fluorescence color,fluorescence intensity, absorption color, transparency, scattering,reflectivity, refractive index, or polarization that is brought about bychemical or physical changes of the material. The material can include apolymer and/or additives that exhibit the optically induced physical,thermal, or chemical changes leading to changes of their opticalproperties.

In other embodiments, the active data storage layers can include a hostpolymer material and a fluorescent dye. The fluorescent dye can bereversible by exposure to light between a first condition exhibiting afirst fluorescence and a second condition exhibiting a secondfluorescence different from the first fluorescence. The fluorescent dyecan also be bleached by exposure to light. The fluorescent dye can beone of an excimer-forming, fluorescent dye, an aggregachromic dye, or aphotobleachable fluorescent dye. In one example, the fluorescent dye isa cyano-substituted oligo(phenylene vinylene) dye.

In still other embodiments, the active data storage layer can include ahost polymer material and an inorganic nanoparticle and/or dye. Theabsorption, photoluminescence, or refractive index of the active datastorage layer can be modified or changed by exposure to light.

In other embodiments, the optical information storage medium can be usedfor storage of images or an image in a color shifting film oninformation bearing documents, or in a diffractive multilayer film forproduction of hologram or hologram-like properties.

Other objects and advantages and a fuller understanding of the inventionwill become apparent from the following detailed description of thepreferred embodiments and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of an optical information storagemedium in accordance with an aspect of the application.

FIG. 2 is a graph illustrating various separations between data layers(y-axis) and the signal to noise ratio (SNR) of a storage mediumaugmented as the layer containing the data is made smaller (x-axis).

FIG. 3 is a schematic illustration of an optical information storagemedium in accordance with another aspect of the application.

FIG. 4 illustrates a schematic of the co-extruder used to manufacturethe multilayer films.

FIGS. 5(A-B) illustrate (A) chemical structure of the dye (C18-RG). (B)Absorption of the entire 200 μm thick ML film, containing 64 activelayers, and the FL spectra of a single layer before and after writingindicating a typical level of FL reduction induced by writing.

FIGS. 6(A-B) illustrate (A) patterned images stored in the 23 layer film(false color). Top left is the uppermost layer and bottom right is theinnermost layer, with subsequent layers going from left to right. (B)Cross-section of two layers after writing complementary images. The topcross-section is along the blue line, and the bottom along the red line.Images are normalized to the background. Each image is 22 μm square,containing 512 pixels.

FIGS. 7(A-B) illustrate (A) cross-section of single written line in a 5μm thick single active layer. The raw FL intensity was normalized bybackground and averaged over the length of the line. (B) Intensityprofile of the spot at the waist, with a FWHM of 380 nm.

FIGS. 8(A-C) illustrate (A) FL images of a series bits in layer 1 afterrecording layer 1 itself (top), layers 1-5 (middle), and layers 1-10(bottom). Images have the same brightness and contrast settings. FIG.8(B) shows the modulation signal of the images in (A). FIG. 8(C)illustrates the experimentally measured CBR of layer 1 (triangles)versus the number of layers recorded, along with the theoreticalpredictions (squares).

FIG. 9 illustrates a top plan view of an optical disc in accordance withan embodiment.

FIG. 10 illustrates an expanded cross-sectional view of the optical discof FIG. 9.

FIG. 11 illustrates an expanded cross-sectional view of the optical discin accordance with another embodiment.

FIG. 12 illustrates an expanded cross-sectional view of the optical discin accordance with another embodiment.

FIG. 13 illustrates an expanded cross-sectional view of the optical discin accordance with another embodiment.

DETAILED DESCRIPTION

Embodiments of this application relate to an optical information storagemedium and to a method of forming the optical information storage mediumusing a multilayer extrusion process. The optical information storagemedium includes a multilayer film that can be provided in a variety offormats (e.g., disks, rolls, cards, stickers, paper, or laminated ontoflexible or non-flexible substrates) with total writable areassufficient for up to petabyte-scale data capacity when used, forexample, in digital optical data storage. The reading/writing orrecording of the data, such as bits, images, shapes, and holograms, canbe performed with existing read/write technology (e.g., existing lasertechnology) and other appropriate permanent or reversible one- ormultiphoton, linear, nonlinear, or threshold optical writing processesor schemes. The combination of appropriate permanent or reversible one-or multiphoton, linear, nonlinear, or threshold optical writing schemesand layering of the physical medium enables data, localized in threedimensions, to be written and subsequently repeatedly read withsubstantially improved signal-to-noise compared to existingtechnologies. The multilayer extrusion process used to fabricate theoptical information storage medium can provide a multilayer film thatincludes from tens to hundreds of layers at a marginal cost peradditional layer, yielding very high capacity data storage at a lowcost.

FIG. 1 is a schematic illustration of an optical information storagemedium 10 in accordance with an embodiment of the application. Theoptical information storage medium 10 includes a multilayer film 12 thatis formed from a plurality of extruded alternating active data storagelayers 14 and buffer layers 16. The buffer layers 16 can separate theactive data storage layers 14 to provide a well defined separation orbuffering between the active data storage layers 14, which allows forprecise location of the data during reading or writing the data, reducedinterlayer cross-talk, and reduced parasitic absorption during writingor reading of the active data storage layers 14.

The active data storage layers 14 can include a thermo-sensitive,photosensitive, or otherwise changeable material that is amenable tooptical writing and reading schemes. In some embodiments, the materialcan undergo an optically induced or thermally induced localizedreversible or irreversible change of optical properties as a result ofthe writing process. The localized change in optical properties candefine data voxels in the active data storage layer that can be readusing an optical reading device. The reversible or irreversible changein optical properties can include, for example, a reversible orirreversible change of fluorescence color, fluorescence intensity,absorption color, transparency, scattering, reflectivity, refractiveindex, or polarization that is brought about by chemical or physicalchanges of the material due to the writing process.

By “data voxel” it is meant a three-dimension spatial unit ofinformation encoded in the variations, which can be binary orcontinuous, in at least one optical property including, but not limitedto, strength, spectrum, polarization, phase of the emission, absorption,reflection, and scattering. The data voxels can have any shape orconfiguration and be in the form of, for example, discrete bits, images,shapes, and/or holograms. It will be appreciated that the size and/orshape of the data voxels is limited only by the writing process used toform the data voxels and the size of active storage layers in which thedata voxels are formed. In one example, the stored data voxels caninclude the user data and/or data to control or guide the read/writeequipment. In another example, the data voxels can include images, suchas an image in a color shifting film on information bearing document.

In some embodiments, the active data storage layers 12 include a hostpolymer material and a photo-sensitive or thermo-sensitive additivematerial, such as a photochromic, fluorescent, aggregachromic dopant ordye, and/or particle additives, which is dispersed or provided in a hostpolymer material. Collectively, the polymer material and thephoto-sensitive or thermo-sensitive additive material may form a polymermatrix that can be readily extruded to form the active data storagelayers.

In other embodiments, the polymer material used to form the activestorage layers can be photo-sensitive or thermo-sensitive itself withoutthe addition of a photochromic, fluorescent, aggregachromic dopant ordye, and/or particle additives. Such photo-sensitive or thermo-sensitivematerial can form a polymer matrix that can be readily extruded to formthe active data storage layers.

The polymer material can be any natural or synthetic solid, orhigh-viscosity thermoplastic material that can be extruded or coextrudedand that allows adequate incorporation of the photo-sensitive orthermo-sensitive materials either as part of the polymer molecularstructure or as an additive, or both. The polymer material can also besubstantially optically transparent and allow segregation and/oraggregation of the photo-sensitive or thermo-sensitive materials withinthe polymer. Examples of polymers that can be used are natural andsynthetic polymers, including, but not limited to, polyolefins, such aspolyethylenes (including linear low density polyethylene, low densitypolyethylene, high density polyethylene, ultra high molecular weightpolyethylene) and poly(propylene), cyclic olefin polymers andcopolymers, poly(acrylate)s, such as poly(methyl methacrylate), polymethacrylate, polybutyl acrylate, poly(acrylamide), poly(acrylonitrile),vinyl polymers, such as poly(vinylchloride), poly(vinylidenechloride),poly(vinylfluoride), poly(vinylidenefluoride),poly(tetrafluoroethylene), poly(chlorotrifluoroethylene),poly(vinylacetate), poly(vinylalcohol), poly(2-vinylpyridine),poly(vinyl butyral), poly(styrene)s, copolymers such as acrylonitrilebutadiene styrene copolymer, ethylene vinyl acetate copolymers,polyamides, such as polyamide 6 and 6,6, polyamide 12, polyamide 4,6,polyesters, such as poly(ethylene terephthalate), poly(butyleneterephthalate), and poly(ethylene naphthalate), poly(carbonate)s,polyurethanes, poly(aryl sulfones), poly(phenyleneoxide), as well asblends or composites comprising two or more of the heretofore mentionedor other compounds. Additionally, the host polymer material may be anelastomer, such as styrene-butadiene copolymers, polybutadiene,ethylene-propylene copolymers, polychloroprene, polyisoprene, nitrilerubbers, silicone rubbers or thermoplastic elastomers.

The photo-sensitive or thermo-sensitive additive can include anymaterial that can be readily mixed or dispersed, e.g., melt blended,with or in the polymer material and exhibits a first readable state(e.g., conformance, color, fluorescence, distribution, and/orreflectance) prior to writing with a light source, such as a laser, anda second different readable state, (e.g., conformance, color,fluorescence, distribution and/or reflectance) after writing. In oneexample, the photo-sensitive or thermo-sensitive material can includeparticle additives, such as functional nanoparticles and/ornanoparticles with functional additives on their surface or volume.Examples include semiconductor, metal or glass nanoparticles, such asquantum dots, with or without polymer and/or dye surfactants or dyesdoped into their volumes.

In another example, the photo-sensitive or thermo-sensitive material caninclude any dye that is capable of emitting a different emissionspectrum based upon the state of matter or the environment to which thedye has been exposed. The dye may be, for example, a one-photon,two-photon, or multi-photon absorbing dye, such as a dye that formsexcimers that emit a different emission spectrum, e.g., fluorescence,based upon the relative concentration of the excimers to the hostmaterial or a dye that emits a different spectrum based upon thesupramolecular relationship between the dye and the host material, otherdye molecules or another chemical compound in the optical informationstorage medium, e.g., the buffer layer. The dyes can be used aloneand/or in combination with nanoparticles where interactions between andamong dyes and nanoparticles such as charge and energy transfer can beused to store data. In some embodiments, a dye, such as a fluorescentdye (e.g., a photobleachable fluorescent dye) can be used in combinationwith a plurality of nanoparticles, such as quantum dots.

Examples of fluorescent dyes include, but are not limited to, anexcimer-forming, fluorescent dye and an aggregachromic dye. In someembodiments, the aggregachromic dye can include a cyano-substitutedoligo(phenylene vinylene) (cyano-OPV) dye compound, such as, but notlimited to, cyano-OPV C18-RG, 1,4-Bis-(α-cyano-4-methoxystyryl)-benzene,1,4-bis-(α-cyano-4-methoxystyryl)-2,5-dimethoxybenzene, and1,4-bis-(α-cyano-4-(2-ethylhexyloxystyryl)-2,5-dimethoxybenzene and2,5-bis-(α-cyano-4-methoxystyryl)-thiophene. Examples of other dyes thatmay be used in the active data storage layers are disclosed in U.S. Pat.No. 7,223,988, the entirety of which is incorporated by reference hereinin its entirety.

It will be appreciated that aspects of the application can includecontrolling the emission color of a given fluorescent dye over a widerange by merely tuning, for example, the extent of it stacking betweenthe limiting states of crystalline solid and molecular liquid solution.The emission spectrum of the color tunable, fluorescent dye may shiftany measurable amount between its crystalline solid and molecular liquidstates. The emission spectrum of a color tunable, fluorescent dye in thepolymer material or optical information storage medium depends onseveral factors, such as, the concentration of dye in the host polymer,the solubility of the dye in the host polymer, the polarity of the hostpolymer, the ability of the dye to form aggregates or excimers, thedegree of bathochromatic shift of the dye excimers relative to the hostmaterial or buffer layer, the degree of exposure to heat or light,external pressure applied to the optical information storage medium andthe usage the optical information storage medium has experienced. Otherfactors of particular interest to certain applications include theability to change the emission spectrum of the optical informationstorage medium based on a mechanical deformation. Therefore, a shift inthe emission spectrum of the optical information storage medium mayoccur if the optical information storage medium is subjected tomechanical deformation, a temperature change via heat and/or light,aging of the optical information storage medium, a pressure change or anenvironmental change, such as exposure to a chemical compound, as wellas other factors.

It will also be appreciated that the emission spectrum depends on thechemical and physical interactions of the dye molecules and/or particles(e.g., nanoparticles) with other compounds in the host polymer. Theseinteractions may include dye molecule-dye molecule interactions, dyemolecule-polymer molecule interactions or interactions between the dyemolecule and other compounds and/or particles (e.g., nanoparticles) inthe host material. For example, excimer formation of the dye in the hostmaterial may cause a large bathochromatic shift in the emission spectrumof the optical information storage medium. Subsequent annealing or coldworking, as well as other forces and factors, may reduce the number ofexcimers in the host material and therefore shift the emission spectrummore toward that of the dilute solution of the dye. Other factors mayincrease the number of excimers in the host polymer and result in ashift of the spectrum more toward the spectrum of the crystalline solid.The segregation and aggregation of the dye in the host material may bereversible or irreversible.

The properties and functionality of the dye and/or particlesincorporated in the polymer material may be chosen such that thesolubility and diffusion characteristics of the dye in the polymermaterial meet the desired application. These properties such as thedegree of branching, the length of branching, molecular weight,polarity, functionality, as well as other properties may be used to varythe rate or degree of bathochromatic shift of the emission spectrumbased upon the degree of external stimulation that the opticalinformation storage medium experiences.

In some embodiments, a writing scheme based on one- or two- ormulti-photon absorption can be used to locally modify the fluorescentproperty of the active data storage layer so as to generate or definedata voxels, such as bits, images, shapes, and/or holograms, in theactive data storage layers. For example, the optical information storagemedium can be in the shape of a disk and spun as a laser writing beam isfocused onto the disk that is effective to locally change thefluorescent properties of a voxel in the active storage layers.Alternatively, the optical information storage medium can be keptstationary while the writing beam is moved. During the reading process,a laser source can be used to excite fluorescence that can be collectedby optics and sent through a bandpass filter to a photodetector. Thedetected modulated fluorescence can be converted to a modulated binaryelectrical signal for further processing. Alternately, for systems thatemit more than one color, simultaneous detection and processing ofdifferent fluorescence components by photodiodes with appropriatefilters can be used to enhance the contrast or even the storage density.

In other embodiments, writing and reading of the active data storagelayers can be based on changes in the local refractive indices withinthe active data storage layers. The active data storage layers caninclude, for example, photochromic, crystallizable materials or someother combination of materials whose reflective properties changes whenpatterned and used for writing/reading data. In some embodiments, thewriting beam can change the index of refraction of a voxel by inducing alocal chemical or physical change. In the crystallizable system, thewriting beam can locally address a voxel inducing a change to the localphase of the material. A disk comprising such active data storage layerscan then be read by detection of differences in the reflectivity.Reading can also be performed by imaging or detection of an opticalinterference pattern.

The buffer layers that separate the active data storage layers caninclude an inert material, such as a substantially optically transparentpolymer, that does not include the same photo-sensitive material orthermo-sensitive material as the active data storage layer. The bufferlayers may be devoid of photo-sensitive or thermo-sensitive material, orcan include a photo-sensitive or thermo-sensitive material, or parts ofthe photo-sensitive or thermo-sensitive material used in the active datastorage layers. However, the buffer layer may not change in the same wayor to the same degree as the active layer when the disk is prepared andwritten. In some embodiments, the buffer layers can have a refractiveindex that is matched to the active storage layers to allow the activedata storage layers to be readily written and read.

The polymers used to form the buffer layers can allow the buffer layersto be extruded alone or coextruded with active data storage layers. Thepolymer materials may be the same as or different than the polymermaterials used to form the active storage layers. In some embodiments,the polymer material used to form the buffer layers can be athermoplastic polymer that upon melting has a viscosity that matches theviscosity of the polymer material used to form active data storagelayers and that allows the buffers layers to be coextruded with theactive data storage material. In addition to the polymers noted above,the polymer materials can be an optical polymer, such as an opticalpolycarbonate, optical polyimide, optical silicone adhesive, optical UVadhesive or optical lacquers. Examples of optical polymers includeMacrolon® CD 2005/MAS130, Macrolon® DP 1-1265, Macrofol® DE 1-1 of BayerAG or Duramid® of Rogers Corp., Ultem® of GE Plastics, A1-10® of Amoco,etc. Regardless, the optical properties of the buffer layer do notchange in the same way or to the same degree as the active data storagelayers.

The thicknesses of the active data storage medium layers relative to thethicknesses of the buffer layers can be selected to allow the activedata storage layers to be writable by appropriate permanent orreversible one- or multiphoton, linear, nonlinear, or threshold opticalwriting processes to define data voxels (e.g., discrete bits, images,shapes, or holograms) within the active data storage layers that arereadable by an optical reading device. In some embodiments, thethicknesses can be selected for the appropriate permanent or reversibleone- or multiphoton, linear, nonlinear, or threshold optical writingprocesses, for the wavelength and focal properties of the writing beam,for increasing the information storage density, for decreasinginterlayer cross-talk, for consideration of the optical apparatus usedto read data from the medium, or for any combination of the above. Byproperly designing the thickness of the active data storage layer 14 andthat of the buffer layer 16 and/or the combined thickness of the layers14 and 16, the signal-to-noise ratio (SNR) within the opticalinformation storage medium can be greatly enhanced. The SNR isdetermined by the size of the data voxel and voxel cross-talk, incombination with the noise of the photodetectors. The multilayeredconstruction of the optical information storage medium describedherein—in contrast to conventional monolithic data storagemedia—significantly boosts the SNR, which enables the use of simpler,lower-cost optics.

In some embodiments, the ratio of the thickness of the active datastorage layer (A) to the bilayer (AB) thickness of the active datastorage layer and the buffer layer (i.e., A/(A+B)) can be less thanabout 0.3, less than about 0.2, less than about 0.1, less than about0.09, less than about 0.08, less than about 0.07, less than about 0.06,less than about 0.05, less than about 0.04, less than about 0.03, lessthan about 0.02, or less than about 0.01. In other embodiments, theratio of the thickness of the active data storage layer to the bilayerthickness of the active data storage layer and the buffer layer can beabout 0.3 to about 0.01, about 0.2 to about 0.02, about 0.1 to about0.05. In other embodiments, the thickness of the active data storagelayers can be about 5 nm to about 10 μm and the thickness of the bufferlayers can be about 50 nm to about 100 μm.

The geometry and thickness of the multilayer film as well as individuallayers of the film has pronounced effect on the SNR of the opticalinformation storage medium. By way of example, FIG. 2 illustrates thecorrelation between the ratio of an active data storage layer thickness(A) to the bilayer thickness (AB) and the SNR of a simulated opticalinformation storage medium that includes a fluorescent active datastorage layer. In this simulation, the optical information storagemedium is illuminated by a 405 nm laser diode with 0.85 NA focusingoptics and fluorescence is collected by the same optics and passedthrough a confocal pinhole with 10 μm diameter before being detected bya photodiode with 1 μA dark current. The active data storage layer (A)to bilayer (AB) thickness ratio of approximately 0.1 leads to a factorof up to 350 improvement in the SNR over a monolithic device undercertain write/read conditions. Such an enhancement arises from theconfinement of the active storage data storage medium to thin layers ofwell-defined separation, providing for precise location of the dataduring reading, thereby reducing interlayer cross-talk and parasiticabsorption from layers outside of the focal region. Typically, aconfocal microscope is necessary to read data that is stored in the formof fluorescent voxels. With proper design constraints, however, theoptical information storage medium described herein with such a high SNRcan be operated without the confocal setup or with significantly relaxeddesign constraints on the confocal setup, thereby significantlysimplifying the read apparatus and lowering system cost. Alternatively,the device can offer higher density storage than monolithic designswhile keeping the same SNR.

In some embodiments, the SNR can be exploited to increase data packingdensity with two-photon writing schemes. The multilayer data storagemedium can also employ a threshold one photon writing process that iscompatible with known optical data storage technology and writingschemes. In this design, the optimum A/AB layer thickness ratio ismaintained but overall thickness is matched to the value appropriate fora threshold one-photon writing scheme so that light focused into thedisc writes in only the intended layer.

In a threshold one-photon writing scheme, for example, the active datastorage medium layers can absorb the writing beam by a one-photonprocess leading to a local change in the optical properties, such asrefractive index, absorption, or fluorescence, if the writing laserpower is above a certain threshold value. The threshold, intrinsicallynonlinear, behavior allows localization of data in all three dimensions.It also permits areal storage beyond the diffraction limit, thus leadingto higher areal storage densities. The writing beam for these activedata storage layers can be focused on a single writing layer and inducea local change in the optical properties of the single writing layer,distinct from any changes in surrounding buffer layers or active datastorage layers. In the threshold one-photon writing scheme, a bufferlayer which is substantially transparent to either the writing beam,reading beam or both can be used to reduce absorption of either or bothbeams while propagating to the addressed layer allowing deep layers tobe accessed before the writing or reading beam is substantiallyabsorbed.

The optical information storage medium may be formed using any extrusionprocess. In some embodiments, the optical information storage medium canbe formed using a multilayer coextrusion process. As an example, theoptical information storage medium may be formed by layering of activedata storage layers and the buffer layers in a hierarchical structure asdescribed and disclosed in U.S. Pat. No. 6,582,807, issued Jun. 24, 2003to Baer et al. and U.S. Pat. No. 7,002,754, issued Feb. 21, 2006, toBaer et al, which are incorporated herein by reference in theirentirety. In one embodiment, the optical information storage medium ismade from two alternating layers (ABABA . . . ) of the active datastorage layers (A) and the buffer layers (B), respectively. The activedata storage layers (A) and the buffer layers (B) form a multilayeredcomposite optical information storage medium represented by formula(AB)_(x), where x=(2)^(n), and n is the number of multiplier elementsand is in the range of from 1 to 256 or higher.

A multitude of alternating layers (A) and (B) can form a multilayeredcomposite optical storage medium comprising at least 2 alternatinglayers (A) and (B), preferably at least 16 layers, for example, at least16, 32, 64, 128, 256, 512, 1024, 2028, or more alternating layers. Eachof the layers (A) and (B) may be microlayers or nanolayers. By utilizingthe above described sequence of steps, a 3-D memory device, formed asthe multilayered composite optical information storage medium isobtained. This structure consists of a plurality of active data storagelayers (A) that can carry recorded information and are divided therebetween by a plurality of buffer layers (B). Each buffer layer (B) canbe considered as a substrate for the next active data storage layer (A)to be arranged thereon or as a protective layer if there is no need forfurther active data storage layers.

The multilayered optical information storage medium may alternativelyinclude more than two different layers. For example, a three layerstructure of alternating layers (ABCABCABC . . . ) that has layers (A),(B), and (C), respectively, is represented by (ABC)_(x), where x is asdefined above. A structure that includes any number of different layersin any desired configuration and combination is included within thescope of the application described, herein such as (CACBCACBC . . . ).In such a three-component, multilayered composite optical informationstorage medium, the third layer (C) may constitute an active datastorage layer different from the layer (A) or a buffer layer differentfrom the layer (B). Alternatively, layer (C) may produce a fluorescenceor reflectance that provides a signal, which can be used to maintain aconstant focal depth into the medium during reading or writing.

In the two-component, multilayered optical information storage mediumdescribed above, the optical information storage medium may be preparedby multilayered co-extrusion. For example, the structure may be formedby forced assembly co-extrusion in which two or more layers (A) and (B)are layered and then multiplied several times. A typical multilayercoextrusion apparatus is illustrated in FIG. 4. The two component (AB)coextrusion system consists of two ¾ inch single screw extruders eachconnected by a melt pump to a coextrusion feedblock. The feedblock forthis two component system combines polymeric material (A) and polymericmaterial (B) in an (AB) layer configuration. The melt pumps control thetwo melt streams that are combined in the feedblock as two parallellayers. By adjusting the melt pump speed, the relative layer thickness,that is, the ratio of A to B can be varied. From the feedblock, the meltgoes through a series of multiplying elements. A multiplying elementfirst slices the AB structure vertically, and subsequently spreads themelt horizontally. The flowing streams recombine, doubling the number oflayers. An assembly of n multiplier elements produces an extrudate withthe layer sequence (AB)_(x) where x is equal to (2)^(n) and n is thenumber of multiplying elements. It is understood by those skilled in theart that the number of extruders used to fabricate the structure of theinvention equals the number of components. Thus, a three-componentmultilayer (ABC . . . ), requires three extruders.

The multilayer structure formed by the coextrusion process is in theform of film or sheet, such as a free-standing flexible film or sheet.By altering the relative flow rates or the number of layers, whilekeeping the film or sheet thickness constant, the individual layerthickness can be controlled. This extrusion process results in largearea multilayer films, e.g., feet wide by yards wide, consisting of tensor hundreds or thousands of layers with individual layer thicknesses asthin as 5 nm. The co-extruded optical information storage medium mayhave an overall thickness ranging from about 100 nm to about 10 cm, inparticular from about 25 μm to about 3 cm including any incrementswithin these ranges.

The fabricated multilayered composite optical information storage mediumis suitable for use as a writable, readable, and erasable medium for 3-Ddata or voxels. In one example, an excimer-forming fluorescent oraggregachromic dye within an active data storage layer (A) can bestimulated via light, although alternative stimuli, such as exposure tochemicals or mechanical forces may likewise be used. The writingmechanism includes two-photon absorption properties of the dye, whichallows light-absorption only at the focal point of the writing beam. Aportion of the energy thus absorbed is converted into heat, which inturn causes the dye to disperse locally, i.e., around the focal point,leading to a pronounced, local, fixed change of the emission color.

When, for example, a cyano-OPV C18-RG dye is used in the active datastorage layer (A), the emission can be switched between orange and greento write data to the optical information storage medium and, thus,appropriate filtering can be used to subsequently read the written data.The planar and axial location during reading is determined by thelocation of the reading lens. The axial resolution is enhanced by aconfocal arrangement. The combination of two-photon absorption with atightly focused laser beam of appropriate wavelength allows the writtenvoxel to be located in the axial direction.

When it is desirable to erase part or all of the data written to theoptical information storage medium, the particular active data storagelayers (A) are again exposed to an external stimuli, e.g., light orheat, in order to reverse the dye aggregation, thereby erasing all thedata stored therein. The writing, reading and erasing process can becarried out as many times as desired.

In other embodiments, a non-active layer of material may becoextensively disposed on one or both major surfaces of the multilayerfilm. The composition of the layer, also called a skin layer, may bechosen, for example, to protect the integrity of the optical informationstorage medium, to add mechanical or physical properties to themultilayer film or to add optical functionality to the multilayer film.Materials may include the material of one or more of the active datastorage layers or buffer layers. Other materials with a melt viscositysimilar to the extruded active data storage layers or buffers layers mayalso be useful.

A skin layer or layers may reduce the wide range of shear intensitiesthe extruded multilayer stack might experience within the extrusionprocess, particularly at the die. A high shear environment may causeundesirable deformations in the multilayer film. Alternatively, if localvariation of color is a desired effect, decorative layer distortions canbe created by mismatching viscosity of the layers and/or skins, orprocessing with little or no skins, such that at least some of thelayers undergo local thickness deformations, resulting in decorativecolored effects. A skin layer or layers may also add physical strengthto the resulting composite multilayer film or reduce problems duringprocessing, such as, for example, reducing the tendency for themultilayer film to split during subsequent positioning. Skin layermaterials which remain amorphous may tend to make films with a highertoughness, while skin layer materials which are semi-crystalline maytend to make films with a higher tensile modulus. Other functionalcomponents such as antistatic additives, UV absorbers, dyes,antioxidants, and pigments, may be added to the skin layer, providedthey do not substantially interfere with the desired properties of theoptical information storage medium.

Skin layers or coatings may also be added to impart desired barrierproperties to the resulting multilayer film or optical informationstorage medium. Thus, for example, barrier films or coatings may beadded as skin layers, or as a component in skin layers, to alter thetransmissive properties of the multilayer film or optical informationstorage medium towards liquids, such as water or organic solvents, orgases, such as oxygen or carbon dioxide.

Skin layers or coatings may also be added to impart or improve abrasionresistance in the resulting multilayer film or optical informationstorage medium. Thus, for example, a skin layer comprising particles ofsilica embedded in a polymer matrix may be added to a multilayer filmdescribed herein to impart abrasion resistance to the film, provided, ofcourse, that such a layer does not unduly compromise the opticalproperties.

Skin layers or coatings may also be added to impart or improve punctureand/or tear resistance in the resulting multilayer film or opticalinformation storage medium. Factors to be considered in selecting amaterial for a tear resistant layer include percent elongation to break,Young's modulus, tear strength, adhesion to interior layers, percenttransmittance and absorbance in an electromagnetic bandwidth ofinterest, optical clarity or haze, refractive indices as a function offrequency, texture and roughness, melt thermal stability, molecularweight distribution, melt rheology and coextrudability, miscibility andrate of inter-diffusion between materials in the skin and active datastorage layers and buffer layers, viscoelastic response, thermalstability at use temperatures, weatherability, ability to adhere tocoatings and permeability to various gases and solvents. Puncture ortear resistant skin layers may be applied during the manufacturingprocess or later coated onto or laminated to the multilayer film.Adhering these layers to the multilayer film during the manufacturingprocess, such as by a coextrusion process, provides the advantage thatthe multilayer film is protected during the manufacturing process. Insome embodiments, one or more puncture or tear resistant layers may beprovided within the multilayer film, either alone or in combination witha puncture or tear resistant skin layer.

The skin layers may be applied to one or two sides of the extrudedmultilayer film at some point during the extrusion process, i.e., beforethe extruded and skin layer(s) exit the extrusion die. This may beaccomplished using conventional coextrusion technology, which mayinclude using a three-layer coextrusion die. Lamination of skin layer(s)to a previously formed multilayer film is also possible.

In some applications, additional layers may be coextruded or adhered onthe outside of the skin layers during manufacture of the multilayerfilms. Such additional layers may also be extruded or coated onto themultilayer film in a separate coating operation, or may be laminated tothe multilayer film as a separate film, foil, or rigid or semi-rigidsubstrate such as-polyester (PET), acrylic (PMMA), polycarbonate, metal,or glass.

A wide range of polymers can be used for the skin layers. Of thepredominantly amorphous-polymers, examples include copolyesters based onone or more of terephthalic acid, 2,6-naphthalene dicarboxylic acid,isophthalic acid phthalic acid, or their alkyl ester counterparts, andalkylene diols, such as ethylene glycol. Examples of semicrystallinepolymers suitable for use in skin layers include 2,6-polyethylenenaphthalate, polyethylene terephthalate, and nylon materials. Skinlayers that may be used to increase the toughness of the multilayer filminclude high elongation polyesters and polycarbonates. Polyolefins, suchas-polypropylene and polyethylene, may also be used for this purpose,especially if they are made to adhere to the multilayer film with acompatibilizer.

In other embodiments, various functional layers or coatings may be addedto the multilayer film and optical information storage medium to alteror improve their physical or chemical properties, particularly along thesurface of the film or optical information storage medium. Such layersor coatings may include, for example, slip agents, low adhesion backsidematerials, conductive layers, antistatic coatings or films, barrierlayers, flame retardants, UV stabilizers, abrasion resistant materials,optical coatings, or substrates designed to improve the mechanicalintegrity or strength of the film or optical information storage medium.

In some applications, as where the multilayer film is to be used as acomponent in adhesive tapes, it may be desirable to treat the multilayerfilms with low adhesion backsize (LAB) coatings or films such as thosebased on urethane, silicone or fluorocarbon chemistry. Films treated inthis manner will exhibit proper release properties towards pressuresensitive adhesives (PSAs), thereby enabling them to be treated withadhesive and wound into rolls. Adhesive tapes made in this manner can beused for producing information storage documents, such as bar codes,stickers, and tamper resistant packaging.

The multilayer film and optical information storage medium may also beprovided with one or more conductive layers. Such conductive layers maycomprise metals such as silver, gold, copper, aluminum, chromium,nickel, tin, and titanium, metal alloys such as silver alloys, stainlesssteel, and INCONEL, and semiconductor metal oxides such as doped andundoped tin oxides, zinc oxide, and indium tin oxide (ITO).

The multilayer film and optical information storage medium may also beprovided with antistatic coatings or films. Such coatings or filmsinclude, for example, V₂O₅ and salts of sulfonic acid polymers, carbonor other conductive metal layers.

The multilayer film and optical information storage medium may also beprovided with one or more barrier films or coatings that alter thetransmissive properties of the multilayer film towards certain liquidsor gases. Thus, for example, the films and optical devices of thepresent invention may be provided with films or coatings that inhibitthe transmission of water vapor, organic solvents, O₂, or CO₂ throughthe film. Barrier coatings will be particularly desirable in highhumidity environments, where components of the film or device would besubject to distortion due to moisture permeation.

The multilayer film and optical information storage medium may also betreated with flame retardants, particularly when used in environments,such as on airplanes, that are subject to strict fire codes. Suitableflame retardants include aluminum trihydrate, antimony trioxide,antimony pentoxide, and flame retarding organophosphate compounds.

The multilayer film and optical information storage medium may furtherbe laminated to rigid or semi-rigid substrates, such as, for example,glass, metal, acrylic, polyester, and other polymer backings to providestructural rigidity, weatherability, or easier handling. For example,the multilayer film and optical information storage medium may belaminated to a thin acrylic or metal backing so that it can be stampedor otherwise formed and maintained in a desired shape. For someapplications, such as when the optical film is applied to otherbreakable backings, an additional layer comprising PET film orpuncture-tear resistant film may be used.

The multilayer film and optical information storage medium may also beprovided with shatter resistant films and coatings. Films and coatingssuitable for this purpose are described, for example, in publications EP592284 and EP 591055, and are available commercially from 3M Company,St. Paul, Minn.

Various optical layers, materials, and devices may also be applied to,or used in conjunction with, the multilayer film and optical informationstorage medium for specific applications. These include, but are notlimited to, magnetic or magneto-optic coatings or films; reflectivelayers or films; semi-reflective layers or films; prismatic films, suchas linear Fresnel lenses; brightness enhancement films; holographicfilms or images; embossable films; anti-tamper films or coatings; IRtransparent film for low emissivity applications; release films orrelease coated paper; polarizers or mirrors; and layers for depthtracking, storing metadata or cryptographic information.

Multiple additional layers within the multilayer film, or on one or bothmajor surfaces of the multilayer film are contemplated, and can be anycombination of aforementioned coatings or films. For example, when anadhesive is applied to the multilayer film, the adhesive may contain awhite pigment such as titanium dioxide to increase the overallreflectivity, or it may be optically transparent to allow thereflectivity of the substrate to add to the reflectivity of themultilayer film.

In order to improve roll formation and convertibility of the film, themultilayer film may also comprise a slip agent that is incorporated intothe film or added as a separate coating. In most applications, slipagents will be added to only one side of the film, ideally the sidefacing the rigid substrate in order to minimize haze.

The multilayer film and optical information storage medium may alsoinclude one or more anti-reflective layers or coatings, such as, forexample, conventional vacuum coated dielectric metal oxide ormetal/metal oxide optical films, silica sol gel coatings, and coated orcoextruded antireflective layers such as those derived from low indexfluoropolymers such as THV, an extrudable fluoropolymer available from3M Company (St. Paul, Minn.). Such layers or coatings, which may or maynot be polarization sensitive, serve to increase transmission and toreduce reflective glare, and may be imparted to the multilayer film andoptical information storage medium through appropriate surfacetreatment, such as coating or sputter etching.

The multilayer film and optical information storage medium may also beprovided with a film or coating which imparts anti-fogging properties.In some cases, an anti-reflection layer as described above will servethe dual purpose of imparting both anti-reflection and anti-foggingproperties to the multilayer film and optical information storagemedium. Various anti-fogging agents are known to the art. Typically,however, these materials will contain substances, such as fatty acidesters, which impart hydrophobic properties to the film surface andwhich promote the formation of a continuous, less opaque film of water.

The multilayer film and optical information storage medium may beprotected from UV radiation through the use of UV stabilized films orcoatings. UV stabilized films and coatings include those whichincorporate benzotriazoles or hindered amine light stabilizers (HALS),both of which are available commercially from Ciba Geigy Corp.,Hawthorne, N.Y. Other UV stabilized films and coatings include thosewhich contain benzophenones or diphenyl acrylates, availablecommercially from BASF Corp., Parsippany, N.J. Such films or coatingswill be particularly important when the multilayer film and opticalinformation storage medium are used in outdoor applications or inluminaires where the source emits significant amount of light in the UVregion of the spectrum.

Adhesives may be used to laminate the optical multilayer film andoptical information storage medium to another film, surface, orsubstrate. Such adhesives include both optically clear and diffuseadhesives, as well as pressure sensitive and non-pressure sensitiveadhesives. Pressure sensitive adhesives are normally tacky at roomtemperature and can be adhered to a surface by application of, at most,light finger pressure, while non-pressure sensitive adhesives includesolvent, heat, or radiation activated adhesive systems. Examples ofadhesives include those based on general compositions of polyacrylate;polyvinyl ether; diene-containing rubbers such as natural rubber,polyisoprene, and polyisobutylene; polychloroprene; butyl rubber;butadiene-acrylonitrile polymers; thermoplastic elastomers; blockcopolymers such as styrene-isoprene and styrene-isoprene-styrene blockcopolymers, ethylene-propylene-diene polymers, and styrene-butadienepolymers; polyalphaolefins; amorphous-polyolefins; silicone;ethylene-containing copolymers such as ethylene vinyl acetate,ethylacrylate, and ethylmethacrylate; polyurethanes; polyamides;polyesters; epoxies; polyvinylpyrrolidone and vinylpyrrolidonecopolymers; and mixtures of the above.

Additionally, the adhesives can contain additives such as tackifiers,plasticizers, fillers, antioxidants, stabilizers, pigments, diffusingparticles, curatives, and solvents. When a laminating adhesive is usedto adhere a multilayer film to another surface, the adhesive compositionand thickness can be selected so as not to interfere with the opticalproperties of the multilayer film. For example, the laminating adhesiveshould be optically clear in the wavelength regions that are desired toread/write the optical information storage medium.

In some embodiments, the multilayer films may be provided with one ormore layers having continuous and disperse phases in which the interfacebetween the two phases will be sufficiently weak to result in voidingduring orienting the multilayer film. The average dimensions of thevoids may be controlled through careful manipulation of processingparameters and stretch ratios, or through selective use ofcompatibilizers. The voids may be back-filled in the finished productwith a liquid, gas, or solid. Voiding may be used in conjunction withthe specular optics of the multilayer film to produce desirable opticalproperties in the resulting film.

In still other embodiments, the multilayer film and optical informationstorage medium may be subjected to various treatments which modify thesurfaces of these materials, or any portion thereof, as by renderingthem more conducive to subsequent treatments such as coating, dying,metallizing, or lamination. This may be accomplished through treatmentwith primers, such as PVDC, PMMA, epoxies, and aziridines, or throughphysical priming treatments such as corona, flame, plasma, flash lamp,sputter-etching, e-beam treatments, or amorphizing the surface layer toremove crystallinity, such as with a hot can.

The optical information storage medium described herein can be used orimplemented in any three-dimensional optical data information device. Bythe language three-dimensional it is meant that the optical informationstorage medium contained therein or which itself constitutes the devicehas the ability to store optical data in three dimensions through itsvolume. It will be appreciated, that devices herein may also be used fortwo-dimensional information storage. The information, which may bestored, on the devices may for example be binary digit or bit data thatcan be converted from an electronic signal to an optical signal forstorage. The read optical signal may then be converted back to anelectronic signal. Processes for conversion of electronic signals tooptical signals and vice versa are well recognized in the art.

In some embodiments, the device constitutes simply the opticalinformation storage medium itself, which takes the form of themultilayer film. In other embodiments, the optical information storagemedium may include a substrate onto which or about which the multilayerfilm is located. For example the substrate may be glass, ceramic,plastics or other suitable, preferably inert material. The substrate cantake the form of a protective coating surrounding or containing themultilayer film of the optical information storage medium. In someembodiments, at least a region of the substrate, in the case where itsurrounds or contains the multilayer film, allows the transmission ofelectromagnetic radiation and in particular ultraviolet, visible andinfra-red light. It may be the case that the optical data storage devicetakes the form of a card or disc which may conveniently be inserted intoinformation technology equipment, such as computers, computer operateddevices, hi-fi equipment, video equipment or the like. In such devices atransparent window may be provided within the cover through which datacan be stored (written) or retrieved (read) to or from the device. Forexample, the devices may take the shape or configuration of conventionalcomputer disks, CDs or DVDs. These possibilities are mentioned by way ofexample only and are not intended to be limiting upon the scope of theinvention.

FIG. 9 illustrates an example of an optical disc 100 that can be usedfor recording and storing information in accordance with an embodiment.The optical disc 100 is formed in the shape of a thin, circular plate,such as used for DVD and Blu-ray-type optical disc, and has a diameterof, for example, about 120 mm and a thickness of, for example, about 1.2mm.

The optical disc 100 includes a hole portion or spindle aperture 102 atthe center the optical disc 100 having a diameter accepted according toindustry standards for optical discs (e.g., about 15 mm). The spindleaperture 102 penetrates the optical disc 100 such that the center of thespindle aperture 102 coincides with the center of the whole optical disc100.

Referring to FIG. 10, which is an expanded cross-sectional view of theoptical disc of FIG. 9, the optical disc 100 includes a coextrudedmultilayer film 110 with a first surface 112 and an opposite secondsurface 114. The first surface 112 of the multilayer film 100 islaminated to a substrate 116 with an optically clear adhesive 118. Theopposite second surface 114 of the multilayer film 110 is covered with aprotective cover layer or hard coat 120.

The coextruded multilayer film 100 includes 16 bilayers of active datastorage layers 122 and buffer layers 124 that are used to store data,such as video, audio, software or other data, although the multilayerfilm can include more or less bilayers as well as additional layers. Thebuffer layers 124 can have a thickness of, for example, about 3 μm toabout 20 μm, and the active data storage layers 122 can have a thicknessof, for example, about 0.05 μm to about 1 μm. In exemplary embodiments,the buffer layers 124 have a thickness of about 6 μm and the active datastorage layers have a thickness of about 0.6 μm. In some embodiments,the coextruded multilayer film 110 can be free of tracking features.

The substrate 116 can be formed of a material, such as a polycarbonateor glass, and have a thickness of, for example, about 1.1 mm.

The optically clear adhesive 118 that is used to laminate the coextrudedmultilayer film 110 to the substrate 116 can be optically transmissivein wavelengths for reading and/or writing of the multilayer film andinclude, for example, a pressure sensitive adhesive (PSA) or a curableliquid optically clear adhesives. These adhesives can be provided asliquids that are coated on the substrate 116 prior to laminating thecoextruded multilayer film 110 to the substrate 116 and cured by, forexample, ultraviolet exposure or thermal curing. The optically clearadhesive can have a thickness of, for example, about 10 μm.

The cover layer or hard coat 120 that is provided on the second surface114 of the multilayer film 110 can formed of a material having thatprotects multilayer film 110 from environmental insults and/or impartsor improves abrasion resistance in the resulting multilayer film 110 oroptical disc 120. For example, the cover layer 120 can include particlesof silica embedded in a polymer matrix that is added to a second surface114 of multilayer film 110 to impart abrasion resistance to the film110, provided, of course, that such a layer does not unduly compromisethe optical properties.

The optical disc can be formed by applying the cover layer or hard coatto the coextruded multilayer film, laminating the multilayer film ontothe substrate with the optically clear adhesive, cutting the film tosize and match the substrate, and sealing inner and outer edges of thefilm. In some embodiments, the multilayer film can be cut either beforeor after laminating and can be cut to size using, for example, lasercutting or mechanical cutting. The inner edge the film, which is definedby the spindle aperature, and the outer edge of the film, which isdefined by the disc edge, can be cut to size and sealed to protect themultilayer film from environmental insult. Sealing the edges can beperformed after lamination by, for example, thermal means during a lasercutting process, or at another time, by other heat sealing methods.Sealing can also be performed using a curable adhesive or sealingmaterial.

In some embodiments, the cover layer or hard coat can be applied to themultilayer after laminating the multilayer film to the substrate. Forexample, the cover layer or hard coat can be a curable coating that isapplied to the film using standard film forming and curing methods. Thecover layer or hard coat can also be a film that affixed to the outersecond surface of the multilayer film using an optically clear adhesive,such as a pressure sensitive adhesive or curable adhesive.

In some embodiments, the optical disc can optionally include a servolayer with a guide tracking feature or pattern for a tracking controlsystem (not shown) that provides optical guidance of an optical writingdevice and/or optical reading device during the optical writing processand/or optical reading process. The tracking control system can includea tracking laser that is focused on the tracking pattern and a trackingactuator for controlling the position of an optical reading and/orwriting device, such as a laser, relative to the disc.

In some embodiments, the tracking pattern can include a combination oflands and grooves provided in a spiral pattern on a surface of thesubstrate imparted, for example, by injection molding of the substrate.The substrate imparted with the tracking pattern can serve a servo layerfor the tracking control system for a groove-less or tracking patternfree multilayer film. Tracking of the substrate tracking featuresrequires that overlying adhesive, coextruded multilayer film, and coverlayer have sufficient transparency at the tracking laser wavelength toprovide for a signal to be returned to an optical pickup using,reflected or emitted light.

It will be appreciated that the multilayer film may be attached using anadhesive layer to both sides of the disc substrate with trackingfeatures, such as grooved spiral patterns on both sides of thesubstrate. Writing and reading can be performed from both sides of thedisc simultaneously

In other embodiments, the cover layer and/or the substrate may havetracking features and serve as servo layers. For example, as illustratedin FIG. 11, an optical disc 140 includes a substrate 142 with acombination of lands and grooves provided in a spiral grove pattern 144on a surface of the substrate 142 and a cover layer 148 having a spiralgroove pattern 150. The spiral groove pattern 144 of the substrate 142can be imparted, for example, by injection molding of the substrate 142,and the spiral groove pattern of the cover layer 148 can be provided byembossing. The groove pitch of the grooved cover layer 148 can match thegroove dimensions and pattern on the disc substrate 142.

In other embodiments, one or more intermediate buffer layers of themultilayer film and/or the substrate of the optical disc may havetracking features and serve as servo layers. FIG. 12 illustrates anoptical disc 200 that includes a substrate 202 with a spiral groovepattern 204 on a surface of the substrate 202 and an intermediate bufferlayer 206 with a spiral groove pattern 208. Similar to FIG. 10 thegroove pitch of the grooved intermediate buffer layer can match thegroove dimensions on the disc substrate.

In still other embodiments, as illustrated in FIG. 13, an optical disc300 can include a cover layer 302, intermediate buffer layer 304, andsubstrate 306 with tracking features and that serve as servo layers. Forexample, the cover layer 302, intermediate buffer layer 304, andsubstrate 306 can include a spiral groove patterns 308, 310, and 312,respectively. The groove pitch of the grooved cover layer andintermediate buffer layer can match the groove dimensions on the discsubstrate. Advantageously, providing the cover layer 302, intermediatebuffer layer 304, and substrate 306 with tracking features facilitatestracking of optical discs that include multilayer films with greaternumbers of layers (e.g., greater than 32 layers).

In other embodiments, as shown schematically in FIG. 3, the opticalinformation storage medium 30 can be provided as a long (e.g., 100 m)continuous optical data storage tape 32. The tape 32 can be formed of amechanically flexible multilayer film as described herein that can beprovided on a roll or drum 34. The tape 32 can be fed through aread/write system 36 for reading and writing the tape 32. The read/writesystem 36 can include an appropriate permanent or reversible one- ormulitphoton, linear, nonlinear, or threshold optical device for definingdiscrete data voxels within the active data storage layers of the tape32 and an optical reading device for reading discrete voxels definedwithin the active data storage layers.

In yet other embodiments, the optical information storage medium can beincorporated into or provided on an information bearing document. Theinformation bearing document can include any type of information bearingdocument, including (but not limited to), documents, bank notes,securities, stickers, foils, containers, product packing, checks, creditcards, bank cards, phone cards, stored value cards, prepaid cards, smartcards (e.g., cards that include one or more semiconductor chips, such asmemory devices, microprocessors, and microcontrollers), contact cards,contactless cards, proximity cards (e.g., radio frequency (RFID) cards),passports, driver's licenses, network access cards, employee badges,debit cards, security cards, visas, immigration documentation, nationalID cards, citizenship cards, social security cards and badges,certificates, identification cards or documents, voter registrationand/or identification cards, police ID cards, border crossing cards,security clearance badges and cards, gun permits, badges, giftcertificates or cards, membership cards or badges, and tags. It is evencontemplated that the optical information storage medium may haveapplicability for devices such as, consumer products, knobs, keyboards,electronic components, etc., or any other suitable items or articlesthat may record information, images, and/or other data, which may beassociated with a function and/or an object or other entity to beidentified. Note also that, for the purposes of this disclosure, theterms “document,” “card,” “badge” and “documentation” are usedinterchangeably.

The following example further illustrates the optical informationstorage medium described herein. The example is intended to be merelyillustrative and is not to be construed as being limiting.

Example

This Example describes a co-extrusion process for fabricatingroll-to-roll multilayer (ML) films for high-density optical data storagesystem ODS. This process can easily produce a continuous, completestorage medium hundreds of meters in length and meters in width, readyfor a variety of formats with total writable areas sufficient forterabyte to petabyte-scale capacity. The co-extrusion process is alsolow-cost and far simpler than current manufacturing approaches, such asspin-coating and lamination.

This Example also demonstrates data storage in 23 layers of a 78 μmthick, 100 m long ML tape using a continuous-wave Blu-Ray (BR) laser byfluorescence (FL) quenching of an organic dye. The areal density isfound to be similar to that of commercial discs, and the small layerspacing allowed by a FL-based scheme leads to a bit density of 1.2×10¹²cm⁻³. Given the mechanism and high axial density, the cross-talk duringwriting is also examined. The approach is generic so that materialsalready developed for high-density ODS can be exploited for innovationsincluding “cloud”-scale data storage.

Materials

The chromophore C18-RG was synthesized using a known process. PETGEastar 6763 were obtained from Eastman Chemical Company and used asreceived. A blend of C18-RG and PETG (nominal dye content 2 wt. %) wasprepared using a Haake Rheocord 9000 batch mixer at 230° C. for 5minutes.

Co-Extrusion

The PETG/dye blend and PVDF were loaded into separate hoppers and heatedto 230° C. where the polymers have matching viscosities. The bilayerextruded after these hoppers were sent sequentially through 5 dies. Eachdie cut perpendicular to the bilayers, spread, and stacked the film tomultiply the number of layers by 2. The final film produced was a systemof 64 layers with an overall thickness of approximately 200 μm.

Absorption and Fluorescence

The absorption spectrum was measured using a Cary 500 spectrophotometeron the entire 200 μm thick, ML film with 64 active layers. The FL wasmeasured using the confocal microscope fiber-coupled to an Acton 2300ispectrometer and a Princeton PIXIS 100BR CCD. A square region was firstread using the same parameters as for reading the images (vide infra)except the scan rate was 6 μm ms⁻¹ to reduce the signal-to-noise ratio.Then, the square region was written using the same parameters as forwriting the images and it was rescanned at the lower power to measurethe spectra after bleaching.

Writing and Reading

To write the data, the laser was focused into the film through anOlympus M Plan Apochromat, 100×, 1.4 NA oil-immersed objective. Patternswere recorded using an Olympus FV1000 confocal microscope by scanningthe laser beam along a customized path at a rate of 75 nm ms⁻¹. Theincident power was about 150 μW and the intensity was varied from 1.0 mWμm⁻² (topmost) to 1.5 mW μm⁻² (lowest layer). The reading was performedin the same setup, except at a faster rate and much reduced power (0.01mW μm⁻² at 5 μm ms⁻¹) to avoid destructive read-out. An intensity on theorder of 0.1 mW μm⁻² or greater is required to obtain measurablequenching with sub-ms exposures.

Calculations of the Layer Cross-Talk

The theoretical curves for the bit cross-talk shown in FIG. 8c werecalculated as follows. The relevant parameter, physically, is the ratioof the intensity received at a given bit location during explicitwriting of that bit relative to that obtained during writing of allother bits in all other layers. The simulated bit array consists ofN_(z) layers with a spacing of Δ_(z), each consisting of N_(y) by N_(x)bits, with spacings of Δ_(y) and Δ_(x), respectively. The bit arrayoccupies a volume of size L_(x) by L_(y) by L_(z). The origin is placedat the center of the data array. Assuming a diffraction-limited Gaussianbeam, the reduction in the FL a single bit located at the origin duringexplicit writing of that bit (the signal, S) should be proportional tosome power of the fluence

$S = {C\frac{e^{{- {\alpha N}_{z}}\Delta \; {z/2}}}{\pi \; w_{0}^{2}}}$

where C is a proportionality constant, a is the absorption coefficient,and w₀ is the beam waist. The FL reduction of this same bit duringwriting of all the other bits (the noise, N) is given by the sum:

$N = {{C{\sum\limits_{k = {{- N_{z}}/2}}^{N_{z}/2}\left\lbrack {\frac{e^{{- \alpha}\; N_{z}\Delta \; {z/2}}}{\pi \; w_{0}^{2}}{\sum\limits_{j = {{- N_{y}}/2}}^{N_{y}/2}{\sum\limits_{i = {{- N_{x}}/2}}^{N_{x}/2}{e^{{- 2}{{({i\; \Delta \; x})}^{2}/w_{k}^{2}}}e^{{- 2}{{({j\; \Delta \; y})}^{2}/w_{k}^{2}}}}}}} \right\rbrack}} - S}$

and the 1/e² beam radius, w_(k), at the z-origin when writing layer k isgiven by:

$w_{k} = {w_{0}\sqrt{1 + \left( \frac{\lambda \; k\; \Delta \; z}{n\; \pi \; w_{0}^{2}} \right)^{2}}}$

where n is the refractive index, and A is the writing wavelength. S issubtracted from this to account for the single term in the sum which isdefined as the signal. This can be greatly simplified assuming a highlyfocused beam and a large scan area. However it is more accurate tosimply perform the summation numerically (Matlab). The parameters werechosen to correspond to those used during writing. The bit spacing waschosen as 1.0 μm in both lateral dimensions with all bits being “on”(numerically equivalent to the “on-off” pattern of 0.5 μm spacingproduced by the square wave generator), Δ_(z)=3 μm, N_(x)=N_(y)=40,N_(z)=10, L_(x)=L_(y)=40 μm, L_(z)=27 μm, and w₀=0.32 μm. A beam waistcorresponding to the experimentally observed value of 0.32 μm is used.The result plotted in FIG. 8c is the ratio S/N. S corresponds to themodulation signal, while the total N results in overall constantbleaching, so this ratio can be determined from the experimental data bycalculating

$\frac{\max - \min}{1 - \max},$

where max is the average of the peak values in the modulation and min isthe average of the troughs.

This calculation is intended only as an order-of-magnitude comparison,as there are many other physical processes that must be taken into whendesigning an optimal ML structure, such as multiple reflections. One ofthe primary differences between experiment and theory here is the factthat the beam is scanned continuously and not discretely. Furthermore,for large intensities the bleaching will become sub-linear, which is notaccounted for in the theory. The light scattered at the interfaces andthe inability to control all aspects of the confocal writing system onsmall scales (such as the retrace and sample positioning) alsocontribute to the carrier-to-background ration (CBR). Many of these willincrease the empirical background, decreasing the CBR compared totheory, as observed.

Layer Spacing Limits and Optical Systems

The use of the FL detection schemes allows smaller layer spacingscompare to schemes relying on phase changes and reflection. Anotherlimiting factor is the response function of the reading system itself.The confocal microscope used here, with a 1.4 numerical aperture (NA)objective, is an extreme case. With these optics, the intensity at thedetector plane drops by half if the sample is moved by about 0.1 μmaxially out of the focal plane (for an infinitely small aperture), whichis much smaller than the layer spacing. If instead the 0.85 NA objectivefound in BR players is used, even with an aperture diameter a factor of10 larger than the spot size at the detector, this figure is still only0.89 μm. Thus, while the factors limiting the minimum layer spacing arerelaxed here, the optical limit of the reading system is not yet anissue.

Results

We employed highly transparent multilayer (ML) polymer films with afluorescent (FL) organic molecule in the active layers. The FL mechanismis used because, for the large number of layers produced and recordedhere, coherent cross-talk during reading would occur with reflectiveschemes. The co-extrusion technique used to manufacture these films isillustrated in FIG. 4. In this process, two thermoplastic polymers (Aand B) are heated to form a melt with matching viscosities, and thencoextruded into a bilayer feedblock. The AB bilayer is sent through aseries of multiplication dies, which cut, spread, and stack the melt,doubling the number of layers each time. The process employed in thisExample allows fabricating films up to 36 cm in width and 200 μm inthickness at a speed of approximately 200 m hr⁻¹, which can be scaled upin commercial applications. The production process has broaderapplicability than just to the particular dye/polymer system describedherein, and can be used to realize more sophisticated devicearchitectures, such as multiple functional dopants or distinct layers,or even metal reflective layers that are needed for phase changematerials.

Using this technique, we fabricated a storage system consisting of 23data storage layers interleaved between inactive buffer layers, whichserve to confine the bits within discrete regions. A roll of filmproduced in this Example possessed a writable area factor of 1000 morethan conventional discs. Note that, as a continuous process, the methodcould produce samples of unlimited length. Data storage layer A iscomposed of a transparent host polymer, poly(ethylene terephthalateglycol) (PETG) that is doped with 2.0 wt. % of the fluorescentchromophore 1,4-bis(α-cyano-4-octadecyloxystyryl)-2,5-dimethoxybenzene(C18-RG, FIG. 5a ). Buffer layer B consisted of poly(vinylidenefluoride) (PVDF), is optically inactive and refractive index-matched tolayer A. This material is particularly effective in limiting diffusionof the dye during processing. The average thicknesses of layers A and Bare 0.3 and 3.1 μm, respectively.

C18-RG is a cyano-substituted oligo(p-phenylene vinylene) dye exhibitingboth excimer and monomer states, which we have previously used for ODSby two-photon absorption. If molecularly dispersed in PETG, the monomerexhibits absorption and FL peaks at 450 and 510 nm, respectively. Theexcimer exhibits absorption and FL peaks at 370 and 540 nm,respectively. The absorbance and FL spectra are shown in FIG. 5B, alongwith the FL spectra after photobleaching by 20%, approximately the samelevel used during data writing. Note that the quenching is fairlyuniform in the region of the peaks, indicating no shift in the relativeconcentration of monomers and excimers. In this work, molecularlydispersed dye in PETG was used for data storage by bleaching the greenFL using single photon absorption.

The data writing was performed using a 405 nm continuous-wave laser beamfocused onto the chosen layer, making the process compatible withcompact BR sources. The FL changes caused by writing were observed to bepermanent and stable over the time period of more than 2 years. FIG. 6Adepicts FL images written into the storage layers. The written regionscorrespond to areas of reduced FL intensity (black). Here writing wasperformed using a scanning confocal microscope, layer-by-layer from thelowest to the topmost storage layer. The same confocal microscope andlaser source subsequently collected 3D FL images of the sample at areduced intensity and increased scan rate.

FIG. 6B shows a cross-section of two adjacent layers after writingsimple geometric images. Even though the images are complementary, thedata in each layer is distinct and sufficiently confined to the layer ofinterest. From the images shown in FIGS. 6a and 6b , it is evident thatdata can readily be recorded and retrieved from each of the individualstorage layers. FIG. 6a also shows that the quality of the retrievedimages decreases for the deeper layers due to aberrations, which can beimproved with a longer working distance objective. However, it isreadily possible to retrieve information from 23 layers, which is thelargest number of recorded layers that has been reported in aheterogeneous ML ODS medium.

The axial spacing of state-of-the-art, two to four layer BR discs isgreater than 10 μm in order to limit the coherent cross-talk that occursdue to multiple reflections of the reading beam at the reflective layerand spacer layer interfaces. The FL detection scheme employed heregreatly reduces the multiple reflections as well as emitting at anon-degenerate wavelength, allowing much smaller spacing to be used.Thus, the spacing of our layers (3 μm) is one of the smallest explored.The areal density of ODS, on the other hand, is constrained by the beamwaist at the diffraction limit. To examine the data bit dimension of ourML films, single lines were written into a monolithic film of the activelayer under the same writing conditions as used above. The resultingprofile is shown in FIG. 7. A fit yields a full-width-half-maximum(FWHM) of 380 nm, which is approximately the minimum bit spacingachievable in the current system, and is consistent with thediffraction-limited beam size.

Optical aberrations limit the thickness of BR discs to less than 140 μm.Given the close layer spacing and BR diffraction limited writing, thebit density achievable in our system is estimated to be 1.2×10¹² cm⁻³.Thus, in a commercial disc format, our co-extruded medium is sufficientfor TB storage within the BR system specifications. In particularsetups, flexible films have even been shown to improve stability andwriting speeds. In an alternative roll-based read/write system,approximately 150 m of this film would be needed to achieve petabyte(PB) capacities. Furthermore, one can trade-off fewer layers, to relaxthe optical constraints, for longer lengths which are still easilymanufactured.

A significant factor that determines the minimum bit spacing in both theaxial and lateral dimension is cross-talk, especially for these filmswith a large number of layers that are closely spaced. One attractivefeature of ML films in the context of 3D storage is the confinement ofthe bits in the axial direction, which reduces cross-talk betweenneighboring bits and layers during writing and reading. To directlymeasure the writing cross-talk, an array of bits was written into 10successive layers and the contrast modulation in the middle (“probe”)layer was read as information was written in the others. Similar writingconditions as described above were employed. The laser was modulatedwith a square wave generator to produce on-off bit pairs separated by1.0 μm in both lateral directions, and the total area written (40×40 μm)was larger than the beam diameter in any given layer, so as not tounderestimate the total cross-talk between any two layers. This alsoleads to results that are not dependent on which of the 10 layers ischosen as the probe. A subsection of the FL pattern and modulation afterselect writing steps is shown in FIGS. 8A and B. The main effect ofcross-talk appears to be an overall reduction in the average FL level.

The ratio of signal modulation to the background FL depletion (CBR) isused to quantify the cross-talk. The CBR after writing each of the 10layers (starting with the probe layer) is plotted in FIG. 8C(triangles). The value decreases from 2 to 0.15 with increasing numberof layers, and is in good agreement with numerical simulations(squares). While this is not insignificant, this CBR ratio is more thansufficient to resolve individual bit information, as shown in FIG. 6.Note that the total background depletion is accumulated over many smallexposures, and due to the high numerical aperture of the writingobjective and the inert buffer layers, the fluence in the layer adjacentto one that is being written, is reduced by more than a factor of 10.Thus, exposure while writing the bit of interest is still the dominantcontribution compared to any other single exposure by about a factor of100.

From the above description of the application, those skilled in the artwill perceive improvements, changes and modifications. Suchimprovements, changes, and modifications are within the skill of thosein the art and are intended to be covered by the appended claims. Allpatents, patent applications, and publication cited herein areincorporated by reference in their entirety.

Having described the invention the following is claim:
 1. An opticalinformation storage medium comprising a substrate and a multilayerpolymeric film, the multilayer polymeric film having a first surface andan opposite second surface that extend the length of the multilayerpolymeric film, the second surface being adhered to a surface of thesubstrate, the multilayer polymeric film including a plurality ofcoextruded alternating polymeric active data storage layers andpolymeric buffer layers, the active data storage layers configured toundergo a permanent induced localized nonlinear or threshold change ofoptical properties when written by a one photon or multi-photon opticalwriting process, the buffer layers separating the active data storagelayers with sufficient thicknesses to axially confine at least one datavoxel written by the optical writing process into a single discreteactive data storage layer that is readable by an optical reading device,wherein the buffer layers have an average thickness of 3 μm to about 100μm.
 2. The medium of claim 1, wherein the substrate is rigid orsemi-rigid.
 3. The medium of claim 1, wherein the surface of thesubstrate includes a guide track for optical guidance of an opticalwriting device and/or optical reading device during the optical writingprocess and/or optical reading process.
 4. The medium of claim 1,further comprising a cover layer provided on the first surface of themultilayer polymeric film, the cover layer defining an outer surface ofthe medium.
 5. The medium of claim 5, wherein the cover layer protectsthe first surface of the multilayer polymeric film from environmentalinsult.
 6. The medium of claim 1, wherein the second surface of themultilayer polymeric film is laminated to the surface of the substrateand/or adhered to the surface of the substrate with an adhesive that isoptically transmissive to wavelengths for reading and/or writing of themultilayer polymeric film.
 7. The medium of claim 1, wherein themultilayer polymeric film has an outer edge the extends from the firstsurface to the second surface, the outer edge being sealed to protectthe outer edge from environmental insult.
 8. The medium of claim 1,wherein the outer edge is sealed by heat sealing and/or application ofby application of a sealing material to the outer edge.
 9. An opticaldisc comprising: comprising a substrate, a multilayer polymeric filmadhered to the substrate, and cover layer adhered to the multilayerpolymeric film, the multilayer polymeric film including a plurality ofcoextruded alternating polymeric active data storage layers andpolymeric buffer layers, the active data storage layers configured toundergo a permanent induced localized nonlinear or threshold change ofoptical properties when written by a one photon or multi-photon opticalwriting process, the buffer layers separating the active data storagelayers with sufficient thicknesses to axially confine at least one datavoxel written by the optical writing process into a single discreteactive data storage layer that is readable by an optical reading device,wherein the buffer layers have an average thickness of 3 μm to about 100μm.
 10. The disc of claim 9, wherein the substrate is a rigid orsemi-rigid polymer or composite substrate.
 11. The disc of claim 9,wherein the surface of the substrate includes a guide track for opticalguidance of an optical writing device and/or optical reading deviceduring the optical writing process and/or optical reading process. 12.The disc of claim 9, wherein the cover layer adhered to a first surfaceof the multilayer polymeric film, defines an outer surface of the disc,and protects the first surface of the multilayer polymeric film fromenvironmental insult.
 13. The disc of claim 9, wherein the multilayerpolymeric film is laminated to the surface of the substrate and/oradhered to the surface of the substrate with an adhesive that isoptically transmissive to wavelengths for reading and/or writing of themultilayer polymeric film.
 14. The disc of claim 9, wherein themultilayer polymeric film has an outer edge and an inner edge thatextend from the first surface to a second surface of the multilayerpolymeric film, the outer edge and/or the inner edge being sealed toprotect the outer edge and/or inner edge from environmental insult. 15.The disc of claim 9, wherein the multilayer polymeric film compriseabout 10 to about 100 layers and a thickness of about 15 μm to about 2centimeters.
 16. A method of forming an optical disc, the methodcomprising: providing a multilayer polymeric film having a first surfaceand an opposing second surface, the multilayer polymeric film includinga plurality of coextruded alternating polymeric active data storagelayers and polymeric buffer layers, the active data storage layersconfigured to undergo a permanent induced localized nonlinear orthreshold change of optical properties when written by a one photon ormulti-photon optical writing process, the buffer layers separating theactive data storage layers with sufficient thicknesses to axiallyconfine at least one data voxel written by the optical writing processinto a single discrete active data storage layer that is readable by anoptical reading device, wherein the buffer layers have an averagethickness of 3 μm to about 100 μm; applying a cover layer to a firstsurface of the multilayer polymeric film; and adhering the secondsurface of the multilayer polymeric film to a surface of a substrate.17. The method of claim 16, wherein the second surface of the multilayerpolymeric film is adhered to the surface of the substrate by laminationand/or with an adhesive that is optically transmissive in wavelengthsfor reading and/or writing of the multilayer polymeric film.
 18. Themethod of claim 17, further comprising sealing an outer edge and/or aninner edge of the multilayer polymeric film to protect the outer edgeand/or inner edge from environmental insult, wherein the outer edge andthe inner edge extend from the first surface to the second surface ofthe multilayer polymeric film.
 19. The method of claim 17, wherein thesurface of the substrate includes a guide track for optical guidance ofan optical writing device and/or optical reading device during theoptical writing process and/or optical reading process
 20. The method ofclaim 17, wherein the surface of the substrate includes a guide trackfor optical guidance of an optical writing device and/or optical readingdevice during the optical writing process and/or optical readingprocess.